Foamed polystyrene article



Dec. 15, 1959 J. B. SISSQN 2,917,217

FOAMED POLYSTYRENE ARTICLE Filed April so, 1956 5 Sheets-Sheet i IN V EN TOR. JA MES 5.5/550N.

A TTO/FNEKS.

MMMMJARM Dec. 15, 1959 J. B. SISSON FOAMED POLYSTYRENE ARTICLE 5 Sheets-Sheet 2 Filed April 30, 1956 INVENTOR- JAMEs 5.575501% BY ATTORNEKS- Dec. 15, 1959 .1. B. SISSON FOAMED POLYSTYRENE ARTICLE 5 Sheets-Sheet 3 Filed April 30, 1956 NPM TGJ mhJ IN VEN TOR. JAMESBS/SSON. BY

ATTORNEYS.

Dec. 15, 1959 J. B. SISSON FOAMED POLYSTYRENE ARTICLE 5 Sheets-Sheet 4 Filed. April 30, 1956 we, 9 sq m5 IN VEN TOR.

\ JZMESBS/SSON.

MMMMMRM ATTOIPA/E/J.

Dec. 15, 1959 J. a. SISSON 2,917,217

FOAMED POLYSTYRENE ARTICLE Filed April so, 1956 s Sheets-Sheet 5 IN V EN TOR.

JA MES 5.5/550N. BY

' A TTO/FNEVS.

United States Patent FOAMED POLYSTYRENE ARTICLE James B. Sisson, Carthage, N.Y., assignor to St. Regis Paper Company, New York, N.Y., a corporation of New York Application April 30, 1956, Serial No. 581,430

14 Claims. (Cl. 229-45) This invention relates to laminated sheet material and to methods and apparatus for forming such material. The invention further relates to such material consisting of combined laminae of foamed polystyrene and paper, to novel container constructions formed from such laminated sheet material, and to novel methods for manufacturing same.

The invention, among many other uses, is particularly well adapted for providing a container construction for hot drinks, such container being of the disposable type which can be manufactured inexpensively and in commercially competitive form. The novel laminate for this purpose consists of a flexible foamed polystyrene sheet adhered to a flexible paper sheet, the polystyrene sheet having a substantially continuous and integral skin on both sides thereof and containing throughout and between such skins on opposite sides thereof a multitude of small closed cells. Such polystyrene sheet is formed by extruding foamable polystyrene in the form of a seamless inflated tube, flattening the latter and adhering the paper sheet to the polystyrene sheet formed from such seamless tube. A container formed from this laminate and with the polystyrene side thereof facing interiorly of the container permits the use of a thinner paper than would otherwise be required, for example for containing hot drinks, because of the insulating and waterproof characteristics of the polystyrene which prevents the wetting of the outer layer of paper and reduces the heat which otherwise would be communicated thereto. The extremely light insulation layer of polystyrene bonded to the paper gives adequate strength and rigidity to such thinner paper, there being a mutual strengthening by both of the components of the laminate. Consequently, the cost of the paper is reduced as compared to that which otherwise might be required for this purpose.

Thus the protective character of the polystyrene makes it unnecessary for the paper to be sufficiently strong to resist the full effect of the heat of the hot drink thereupon as was heretofore the case and such polystyrene also makes it unnecessary for the paper to resist the effect of wetting. Better insulating qualities are obtained since dry paper is a better heat insulator than wet paper.

Also the aforedescribed laminate with the polystyrene forming the interior face of such a container prevents the flavor of a hot drink from being changed by the paper and thus prevents the drink from absorbing so-called paper flavor. The polystyrene, due to its inert nature, will not change the flavor of foodstuffs including food liquids.

The novel laminate, as aforementioned, is formed by extruding through a nozzle at an extruding zone formable polystyrene in the form of a seamless tube, which tube is stretched and inflated by a selected volume of gas therein. At a collapsing zone the tube is collapsed into flattened sheet form, the selected volume of gas being situated between the extrusion and collapsing zones. While so collapsing the tube, a continuous flexible web of paper is adhesively applied to at least one side thereof and such collapsed seamless tube can be cut longitudinally to separate the sides thereof either before or after the application of the paper web. The combining of the flexible paper web with the sheet of polystyrene is effected by application of selected pressure which will not unduly crush the multitude of closed cells but will cause smooth adherence of the laminae.

I have found surprisingly that the polystyrene side of the finished laminate can be formed, in the absence of a deliberate embossing thereof, with the appearance of embossing somewhat similar to certain types of leather but with considerably greater softness, the surface being shiny and exhibiting a diffused sheen. Despite this, if desired, the laminate can be deliberately embossed by the application of embossing pressures thereby to obtain preselected and novel embossing effects.

Further I have found that the novel laminate possesses high printability despite any hills and valleys thereof which may or may not be the result of deliberate embossing, this being true by virtue of the particular degree of recovery or particular resiliency of the foamed polystyrene which is unusually well adapted for halftone printing by virtue of the fact that the application of the printing plates thereto under printing pressure causes the hills to be reduced temporarily in altitude at least to the level of the valleys whereby an equal application of the printing ink is made over all the surfaces regardless of relative height from a selected base. Also, in the opinion of those skilled in printing, a third dimensional or depth effect is obtained in printing same, particularly in halftone printing, which apparently is due to the inner porosity of the polystyrene and its shiny surface, such inner porosity affecting the skin surface.

I have found that an infinite color shading of such sheets can be obtained by dry blending oil soluble dyes with the foamable beads of polystyrene before extruding the mixture. I

Also, containers may be made from the novel laminate having an exterior surface of the foamed polystyrene, which surface is cushioned, non-slip, bright, pleasant to the touch and which container is Well adapted for drinking use by virtue of its low heat conductivity in that it will conduct little or nov heat away from the hands or lips and hence produces a feeling of warmth to the touch.

Also I have found by virtue of the better insulating qualities of a container of this nature, that there is no need to provide a handle for same as in the case of disposable hot drink containers heretofore suggested, such as those for hot coffee.

The prior art has failed to suggest an entirely satisfactory laminate which is well adapted for use in insulated containers for liquids, such as hot drinks or frozen foods, one of the reasons being the relatively high cost of materials heretofore suggested for this purpose.

Also, no suitable laminate has been suggested in the past having the qualities of high insulation, bright reflective sheen finish, resistance to stain, as caused by foods, high printability in an embossed or unembossed condition, waterproofness and non-abrasiveness.

One of the objects of the present invention is to overcome the disadvantages or to reduce same to insignificance.

The invention in one aspect thereof comprises a novel flexible laminate constituted by an extruded, stretched, ballooned and flattened tube of flexible foamed polystyrene formed into a flattened sheet several thousandths of an inch thick containing a multitude of closed cells and having a substantially continuous integral skin showing a diffused sheen, one side of said sheet being bonded by adhesive to a flexible sheet of paper.

The invention in another aspect thereof comprises a container formed from the aforementioned novel laminate, the latter having selected marginal surfaces on one side thereof overlapping and secured adhesively to selected marginal surfaces on the other side thereof to form the container, the cells of the foamed polystyrene in those selected marginal surfaces being collapsed, such selected surfaces being in engagement with the selected marginal surfaces on the other side of the laminate which are of paper.

The invention in another aspect thereof comprises a container as set forth in the preceding paragraph and whereinthe polystyrene side of said laminate forms the interior surface of the container.

The invention in a. still further aspect thereof comprises ,the method for forming the aforementioned novel laminated article of foamed polystyrene flexible sheet material adhered to a sheet of flexible paper, which method consistsin extruding foamable polystyrene through a nozzle continuously to form a seamless tube inflated by a selected volume of gas within such tube, collapsing the. inflated tube continuously at a squeeze zone thereby to bring into engagement opposite interior surfaces of such tube, such selected volume of gas being located between the extrusion and squeeze zones. The collapsing of the seamless tube thereby forms two adjacent sheets of the flexible foamed polystyrene material, which sheets are joined along their sides. Each of said adjacent sheets, as aforementioned, is several thousandths of an inch thick and contains throughout a multitude of closed cells. A continuous integral skin exists on both sides thereof between which the aforementioned multitude of closed cells are located. While so collapsing the seamless tube and to at least one side of the collapsed portion thereof there is continuously and adhesively applied a flexible paper web at a combining Zone and by the application of pressure which urges together the paper web and the sheet of polystyrene, the pressure being selected to effect a. bond without crushing the closed cells of the foamed polystyrene. The sides. of the collapsed seamless tube are separated as by cutting apart either before or after the application of the paper web to one of said sheets of polystyrene. 1

Further objects, features and advantages of the present invention will appear from the detailed description given below taken in connection with the accompanying drawings which form a part of this specification and illustrate, by way of example, certain preferred embodiments of the invention, it being understood that the latter is not limited by such drawings, reference for this latter purpose being had to the appended claims.

In the drawings:

. Fig. l is a side view, partly in section and with parts broken away, illustrating schematically an apparatus for carrying out one form of the present invention;

Fig. 2 is another side view, partly in section and with parts broken away, illustrating also schematically an apparatus partly similar to that shown in Fig. 1 but embodying a modification thereof;

Fig. 3 is a side elevation schematically indicating a still further modification of the apparatus of Fig. 1 and showing a different manner of applying continuously paper webs to the sheet of polystyrene;

Fig. 4 is a side elevation illustrating a still further modification of the apparatus of Fig. 1 and showing another manner of applying continuously a paper web to the polystyrene;

Fig. 5 is a fragmentary cross-sectional view of a laminate embodying one form of the present invention shown upon a greatly enlarged scale and illustrating one form of the embossing of the foamed polystyrene sheet;

Fig. 6 is a top plan View on an enlarged scale of another form of the novel laminate indicating a different embossing of the polystyrene sheet thereof;

Fig. 7 is asec'tional view taken substantially along line 7-7 of Fig. 6 but on a greatly enlarged scale with respect to Fig. 6;

Fig. 8 is a plan view of a container blan or strip of the novel laminate which has been prepared for winding into a container or an element of a container;

Fig. 9 is a perspective view of a cylinder which is formed by helically winding the strip shown in Fig. 8;

Fig. 10 is a vertical cross-sectional view of a container employing the cylinder shown in Fig. 9;

Fig. 11 is a sectional view on a greatlyenlarged scale taken substantially along line 11-11 of Fig. 9 and showing a novel seam construction;

Fig. 11a shows a modification of the seam construction of Fig. 11;

Fig. 12 is a plan view of another container blank formed from the novel laminate;

Fig. 13 is a vertical sectional view of a container formed from the blank shown in Fig. 12; and

Fig. 14 is a showing of a foamed polystyrene sheet bearing a printed image produced as by half-tone printing thereon and embodying one form of the present invention. v

Referring to the drawings in greater detail, with particular reference to Fig. 1, there is shown an apparatus for carrying out one form of the novel method for forming the novel laminate. T he apparatus comprises an extruder element 20 of well known construction comprising a barrel 21 within which there is rotatably mounted an extruder screw 22 which is driven by suitable power means not shown and whichreceives at its lefthand extremity the foamable polystyrene which is placed in a hopper 23. The polystyrene is extruded through an extruder nozzle 24 which, in the form shown, has an orifice of annular configuration. A central conduit 25 is employed for a purpose to be mentioned below. Heat is applied to selected portions of the extruder element 20. The extruder screw 22, as a result of being turned and with the aid of such heat, urges by extrusion the foamable polystyrene through the nozzle 24 in the form of a seamless tube 26 into which there is directed gas under pressure, such as air, via the passage 25 for the purpose of stretching and inflating the tube 26 so that it is ballooned to aselected diameter. Such stretching occurs extremely rapidly both longitudinally and circumferentially and thus is bidirectional. r

r The thickness of the foamed polystyrene sheet thus formed will normally vary between .005'and .060" but may be up to 0.125" if necessary. The multitude of closed cells normally vary in diameter between .002" and .006". I

The seamless tube 26 is continuously directed to, a collapsing unit 27 where the sleeve is progressively flattened by means of the sets of rollers and 29 whichprogressively bring the opposite sides of the sleeve together and direct same into the nip of a pair of squeeze. rolls 30, 31 which completes the flattening of the tube 26 andfrom which the now flattened polystyrene double web 32 is directed toward a combining unit 33 where there are continuously applied to the opposite faces of such web 32 a pair of continuous paper webs 34 and 35, respectively. For this purpose the web 32 and the webs 34 and 35 are directed into the nip of a pair of combining rolls 36 and 37 which combine with the aid of adhesive each of the webs to its respective polystyrene surface. The squeeze rolls 30, 31 and combining rolls 36 and 37 are urged together by a preselected force or pressure which will effect respectively a suitable collapsing of the tube 26 anda suitable adhesion between the several layers but which will not unduly crush any of the multitude of cells in the polystyrene. The combining rolls 36 and 37 respectively are mounted upon shafts 38 and 39. I have found it advantageous to urge such shafts toward one anotherresiliently with aforce equal to approximately one-half pound per inch of the width of the paper web.

: In'order'toeffect the bond between the polystyrene web 32 and the paper webs 34 and 35, adhesive is applied, for example, to the inner faces of the webs 34 and 35, respectively, by means of adhesive applicators 40 and 41. If desired, such adhesive can be applied to the web 32 instead of to webs 34, 35. The adhesive advantageously is a synthetic resin having a polyvinyl acetate base.

There is thus formed a double layer of the novel laminate consisting of the web 32 comprising the fiattened foamed polystyrene tube joined along its opposite edges and bearing on its opposite outer faces the aforementioned webs 34 and 35 which preferably are of paper but can be of other suitable sheet material. Such two adjacent thicknesses of the novel laminate are made separable by any suitable means, such as by a pair of slitters located respectively on opposite sides of the flattened tube for cutting such opposite sides, one of such slitters being shown at 42.

If desired, the double thickness of the novel laminate can be cut into any desired lengths by means of a cutter 43 consisting of an anvil 44 and a reciprocating cutter 45.

It will be noted that the paper webs 34 and 35 are drawn respectively from source rolls 46 and 47, respectively.

During the initial stage of the extruding of the seamless tube 26, air or other gas under pressure is directed therein via the passage 25 While the tube progresses toward the collapsing unit 27. After the initial edges of such tube have been collapsed by the collapsing unit 27, the air under pressure from the passage 25 should be shut off to avoid rupturing the seamless tube. Alternatively, air can be directed continuously into the tube providing it is withdrawn at a comparable rate thereby to avoid rupturing of thetube. If desired, a cooling gas can be so directed continuously into the seamless tube and continuously withdrawn via another passage (not shown).

In Fig. 2, the apparatus and the method performed are identical with that of Fig. 1 with the exception that paper webs 34a and 35a, analogous respectively to the webs 34 and 35 of Fig. l, are applied to the web 32 at squeeze zone 27a and thus are directed on opposite sides of said web into the nip of a pair of squeeze rolls 30a and 31a, analogous to rolls 30, 31 of Fig. l. The-squeeze rolls 30a and 31a thus .servethe dual function of .collapsing the tube and pressingthe paper webs upon opposite faces thereof, it being understood that suitable resilient means are employed for urging same together which are analogous tofthose employed for combining rolls 36 and 37.

Referring now to Fig. 3, in lieu of so applying the paper webs, as shown in Figs. 1 and 2, the web 32 comprising the continuous collapsed polystyrene seamless tube in advance is separated into two polystyrene webs, that is, vthetwo flattened sleeve surfaces thereof are cut apart as by a pair of slitters situated on opposite edges thereof, one of which is shown at 48, thereby forming the two separate polystyrene Webs 32a and 32b which are directed into the nip between peripherally engaged rolls 49 and 50 which, if desired, can have embossed surfaces for the purpose of acting upon the two webs with suitable embossing pressure to produce, for example, an embossing such as that shown in Figs. 6 and 7. However, the rolls 49 and 50, if desired, can be free of such embossing.

The separate polystyrene webs 32a and 32b, after being directed between rolls 49 and 59, are directed around the righthand half thereof, as viewed in Fig. 3, and thence respectively around the lefthand half of rolls 51 and 52 which are respectively urged against the rolls 49 and 50. The axes of the rolls 49, 50 and 51, 52 are preferably in alignmenhas shown in Fig. 3.. Paper Webs 53 and 54 are respectively applied to the surfaces of webs 32a and 3217 which formerly comprised the inside of the tube 26, this being accomplished by directing such paper webs 53 and 54, respectively, into the nips between the roll pairs 49, 51 and 50, 52. Adhesive is applied to the pertinent'surfaces of the webs 53, 54 by means of adhesive applicators .55, 56.

The rolls49, 50, if conformed as embossing rolls with suitable embossed surfaces, if desired, can have heat applied thereto for the purpose of assisting in forming the embossing of the polystyrene webs 32a and 32b. I

Whereas in Fig. 3 the paper webs 53 and 54 are applied to the surfaces of the polystyrene webs which were located inside the tube 26, the apparatus shown in Fig. 4, is similar to that of Fig. 3 except that it is designed for applying paper webs 53a and 54a to the surfaces of the polystyrene which formerly comprised the outer surface of such seamless tube 26. Accordingly, a pair of combining rolls 57, 58 are provided for webs 53a and 32a, such combining rolls being situated to urge together the webs wherein the paper web is situated exteriorly of the web 32a as viewed in Fig. 4. Analogously, a pair of combining rolls 59 and 60 are provided for combining the webs 32b and 54a. Adhesive applicators 61 and 62 respectively apply adhesive to the webs 53a and 54a.

Referring now to Fig. 5, I have found that the novel laminate can be embossed in such a manner that the polystyrene and not the paper lamination contains the embossing. This is accomplished by subjecting the novel laminate to embossing rolls wherein the principal embossed surfaces thereof are formed on the rolls which contact only the polystyrene side thereof, the other roll comprising a backup roll for the embossing roll being in engagement with the paper side of the laminate. Thus the polystyrene layer can be embossed without embossing the paper layer. This can be accomplished, for example, by embossing the roll 58 (Fig. 4) and employing a smooth surface upon the roll 57. 1 1

Referring to Figs. 6 and 7, where a more pronounced type of cushion construction is desired, a more pronounced cushion type of embossing of the polystyrene layer is effected, the other layer being free of embossing. Under these circumstances I have found it advantageous, as aforementioned, to emboss the polystyrene sheet prior to combining same with the paper as by conforming the surfaces of rolls 49 and 50 to produce the embossing. By so embossing the polystyrene layer prior to combining same with the paper, a plurality of mounds 63 can be formed separated by valleys, such as 64. The polystyrene sheet, for example, 32a (Fig. 7), is in engagement with the paper web 53 at the under. portions of the valleys 64,-for example, in the areas 65 and. 66, the higher portions of the under surface of the web 32a being out of engagement with the paper web 53 thereby insuring the forma tion of a laminate having cushion-like characteristics which are adapted for certain uses, such as forming interleaves for the shipping of plate glass.

Referring now to Figs. 8, 9 and 10, the formation of a novel container embodying one form of the present invention will now be described. The principal element of a container which is formed as shown in these figures comprises cylinder 67 which is formed by helically winding a strip 68 formed of the novel laminate. The strip 68 formed from the novel laminate is fabricated in accordance with any of the methods and by any of the apparatus heretofore described and consists of an elongated ribbonlikepiece having the ends thereof tapered in a well known manner to adapt same for the formation of the cylinder For the purpose of forming a novel seam for such cylindrical container element 67, I have found it advantageous specially to prepare a margin 69 of the strip 68 whereby the scam in Fig. 11 is produced as a result of helically winding the strip 68 and adhering the marginal portions thereof as will be described herebelow. Thus-I have found it advantageous to collapse the multitude of small closed cells along selected marginal surfaces of the strip 68 for the purpose of forming there solid polystyrene thereby increasing the strength of the internal structure of the polystyrene. The foamed polystyrene having the multitude of discrete closed calls is relatively not so-strong for adhesion purposes as such llscd.. O d.PQ y Yrne.

Consetiuently, "after such S rip 68 is fcrmed, h selcied 'rnargin, sucha's'69, i's'pa ssed between heated rolls and '71 whichthereby apply heat'and pressure to collapse the small closedcavities in the polystyrene'of such "margin 6!! and to fu'se'th'e polystyrene into'a thinsolidribbon-like s-r Thereafter the strip is wound 'helically'into the cylindrical configuration shownin Fig. 9 with the polystyrene side of the 's'trip facing interiorly and wherein the solid or "fused polystyrene m'arg'in 69a is adhesively secured to the paper sideof the strip 68 "along "an opposite marginal portion 72 located on the opposite'side of the strip with re- "spect'to the polystyrene side, it being understood that 'ad- 'hesive is applied to one or the other 'of'the facing marginal portionsf 69a'or 72 prior to the winding of the strip into the cylinder 67.

77 by an adhesive'layer 80 therebetvveen. If desired, the '1ayer'79 along the'rnargin can be collapsed to reduce the bulkof the seam but this'is not necessary'toenhance'the strength of the'bond'betw'een thicknesses 73 and 76.

'Iha've found that the application of heat'andpressure,

as by the heated rolls 70, 71 to the strip margin 69 forms a bead 81'alo'ng the inner 'edge'of the solid polystyrene margin'69a, which bead serves the purpose of forming a well defined boundary for accurately positioning theedge 82'of the paper margin 72 in the formation of the seam of Fig. 11. Furthermore, the bead 81 assist in the sealing of the seam by forming with'edge82 a 'welldefined trough Ihave/found "that advantageous conditions for collapsing'or fusing the-polystyrene of the margin "include the applicationofhe'at in excess of 250 F. andapplica- 'tion of pressure in excess of 'one pound per inch of 'heated'roll width. Preferably the heated roll'is coated with an adhesiverepellentmateri'al suchas polytetrafiuorethylene. The novel seam, in one form thereof, may be formed without any'or anyappreciable amount ofadhesive in the trough 83. 'Alternatively in another form; adhesive 78a'up to' the level 78b may be deposited or caused to collect in the trough '83. The adhesive, up to level 78b, thus entirely bridges the gap between the polystyrene bead 81 and the polystyrene layer 79 and hence prevents the contents of the container from contacting the edge 82of the paper layer 77. Where the adhesive employed is waterproof or'water-repellent there is thus provided a seam construction of special advantages in view of the waterproof character of the polystyrene, because the interior of a container having such a seam is entirely faced with waterproof material. Normally such a waterproof or water-repellent adhesive is employedas above suggested. The seam 'of Fig. ll with or without the adhesive 78a 'in the trough 83 is of substantial structural strength. Also, even if formed without such adhesive 78a suchseam is for most purposes substantially waterproof or liquid-tight, depending of course on the liquid absorptive qualities of thepaper layer 77 and the area of the exposed edge 82.

The cylinder 67 can be completed thereby'forming a 86 which is held between the outer surface of the cylinder 67 and the in-rolled portion 84. The bottom-forming disk preferablyis composed of the novel laminate-and 'is positioned with the polystyrene side thereof facing interiorly'oftlie'container.

It'gis', of course, possible to form the container of Fig. 10 with the polystyrene side of the novel laminate facing outwardly instead of inwardly, in a separate and nonanalogous form of the invention.

A container top 87 also formed of the novel laminate may be provided for the container of Fig. 10.

The novel laminate also can be formed in many other shapes for the purpose of forming boxes or other types of containers. Referring to Figs. 12 and 13, another example of a container is shown formed from the novel laminate, a so-called blank 88 comprising a section of an annular fiat disk being adapted for the formation of the container shown in Fig. 13. The marginal portions 89 and 90 are prepared in a manner similar to that described above in connection with Fig. 11, that is, the multitudinous cavities in the foamed polystyrene are collapsed and the blank 88 is wound into a convolutelike conformation shown in 'Fig. 9 wherein margin 90 containing the collapsed polystyrene is moved into overmation of a scam in other Ways than those above set forth. For example, as follows:

(1) The application of pressure and a solvent to the polystyrene marginal portions to collapse the cells thereof without heat.

(2) The removal of the foamed polystyrene along such selected marginal portions by the use of a solvent,

for example, acting upon a roll which engages such portion and entrains same upon the roll, thepolystyrene being removed from the roll as by a doctor blade.

(3) The removal of the foamed polystyrene along the selected margin, for example, by abrasive means.

Referring now to Fig.'11,-a novel seam construction is shown which is formed in accordance with the above numbered-paragraphs 2 and 3. Such seam construction is similar to that shown in Fig. 11 with the exception that the solid polystyrene marginal layer 69a is omitted and the head 81 is not formed. The formation of the head 81 is the resultof the application of heat and does not occur if the marginal polystyrene is removed by a solvent or by abrasion. Thus the seam of Fig. 11a consists of a thickness 94 consisting of a marginal paper layer 95 adhered by an adhesive layer 96 to a thickness '97, the latter being similar to thickness 76 in Fig. 11

andconsisting of'a paper layer 98 adhered by adhesive 99 to a foamed polystyrene 1ayer'100. Thus paper layer 95 is adhered to paper layer 98. The positioning of the foamed polystyrene which formerly existed along the marginal portion of the lower thickness of the seam of Fig. 11a is indicated in broken lines at 101 and has been previously removed as by a solvent or by abrasion as aforementioned. The balance of such polystyrene layer remains intact as at 102 and is adhered to the paper layer 95. Lefthand face 103 of the polystyrene layer 102 thus serves a-function somewhat similar to the bead 81 of Fig. .11 in that it provides a Well defined boundary for the positioning of edge 104 of the paper layer 98 and provides between the faces 103 and104 a trough 105 which may be filled'with adhesive if desired up to the top level of the polystyrene 102 as viewed in Fig. 11, thereby preventing access of liquids to the edge 104 of the paper layer 98.

Referring now to Fig. 14, there is shown a layer of the foamed polystyrene formed as by the extruding apparatus shown in- Fig. 1 and having imprinted thereon an image by half-tone printing and illustrating a three dimensional 9 or depth eifect obtained by the coaction of the printed image and the polystyrene sheet.

There is thus provided a novel laminate which is particularly well adapted for container or carton constructions with special reference to containing hot drinks.

The novel laminate is also particularly well adapted for half-tone printing due to its degree of recovery after printing and due to the glossand shine of its skin surface.

The novel laminate is also easily embossable and after undergoing embossing is easily printable because of the yielding and recovering nature of the polystyrene.

Regarding the embossing of the novel laminate, any desired embossing effect can be produced by employing an embossing roll having a surface formed to create such effect. Such roll can be employed as the pressure roll for producing adhesion between the foamed polystyrene sheet and the paper after the adhesive has been applied to one or the other.

The appearance and non-abrasive character of the novel foamed polystyrene adapt same, for example, as the lining for containers, such as jewelry boxes or instrument containers. Its non-abrasive character and extremely high angle of slip make it of high utility as interleaving between polished or easily damaged surfaces, for the packing of polished metal and for the packing of plate glass.

The high printability, cushioning and waterproof properties of the foamed polystyrene sheet also adapt same for many other uses, such as labels for glass containers of chilled liquids. The foamed polystyrene sheet is also of high utility as an interleaf placed between steel surfaces because of its high angle of slip which has been found to be in excess of 60 as between the steel and the foamed polystyrene.

Although the disclosure above set forth is particularly concerned with the lamination of the polystyrene sheet with paper, the invention is not limited thereto, it being possible in separate and non-analogous forms of the invention to bond the foamed polystyrene sheet to other flexible rollable materials, such as metal foil, or cloth, or some other plastic.

Substantially wrinkle-free laminate embodying the present invention can be formed on a commercial scale by means of the apparatus herein disclosed wherein the adhesion between the foamed polystyrene and the paper or other sheet material is accomplished in a smooth wrinkle-free manner.

What is claimed is:

l. A flexible laminated article comprising a flexible sheet of polystyrene less than about 125 thousandths of an inch thick of foam-like consistency containing a multitude of closed cells and having a substantially continuous integral skin showing a bright gloss and bonded on one face thereof to a flexible sheet of paper by adhesive, said sheet being of substantially uniform thickness.

2. A flexible laminate consisting of a flexible sheet of foamed polystyrene between about and about 60 thousandths of an inch thick adhered to a sheet of flexible material and bearing thereupon printed designs and lettering.

3. An article of sheet material comprising a flexible sheet of polystyrene between about 5 and about 60 thousandths of an inch thick having on opposite surfaces thereof an integral continuous skin and containing throughout between such skin surfaces a multitude of closed cells, said sheet material bearing an image thereupon formed by half-tone printing, the skin of such sheet material having a bright gloss being visible between the dots of the half-tone printing.

4. A container formed of laminated sheet material consisting of a sheet of flexible foamed polystyrene secured by a layer of adhesive to a flexible sheet of paper; said laminated sheet having overlapping marginal portions to form such container; said polystyrene sheet being less than about 60 thousandths of an inch thick, having on each of opposite surfaces thereof a substantially integral continuous skin and containing throughout and between such skin surfaces a multitude of small closed cells; an adhesive layer between such overlapping marginal portions of such laminated sheet material thereby forming the seams of such container, the cells of said foamed polystyrene being collapsed on those sides of such marginal portions which are in engagement with the paper side of other marginal portions of said sheet material.

5. A container formed of a laminated sheet material comprising a flexible sheet of foamed polystyrene between i about 5 and about 60 thousandths of an inch thick con taining throughout a multitude of small closed cavities and bonded by adhesive to a flexible sheet of paper; said sheet material having selected marginal surfaces thereof in engagement and overlapping and secured to one another for forming such container; and an adhesive layer between such overlapping surfaces for so securing same; the cells of said foamed polystyrene being collapsed along such select marginal surfaces which are in engagement with such overlapping marginal surfaces.

6. A container formed of a laminate comprising a tube of foamed polystyrene formed into a sheet several thousandths of an inch thick containing throughout a multiude of closed cells and having a substantially continuous skin showing a gloss, said sheet being bonded by an adhesive to a sheet of paper to form such laminate; said laminate having selected marginal surfaces on one side thereof overlapping and secured adhesively to selected marginal surfaces on the other side thereof to form such container; the cells of said foamed polystyrene being collapsed in those selected marginal surfaces which are in engagement with the selected marginal surfaces on the other side of the laminate which are of paper.

7. A container formed of a laminate comprising a tube of foamed polystyrene formed into a flattened sheet between about 5 and about 60 thousandths of an inch thick containing a multitude of closed cells and having an integral continuous skin, said sheet being bonded by an adhesive layer to a sheet of paper to form such laminate; said laminate having selected marginal surfaces thereof bonded adhesively to form such container; the polystyrene side of said laminate forming the interior surface of said container; those of such selected marginal surfaces which bear polystyrene having the cells thereof collapsed to form substantially solid plastic.

8. A container formed of sheet material consisting of a sheet of flexible foamed polystyrene having engaged marginal portions to form such container; said polystyrene sheet being several thousandths of an inch thick, having on each of opposite surfaces thereof a substantially integral continuous skin showing a bright surface and containing throughout between such skin surfaces a multitude of small closed cells of the order of .002" to .006" in diameter.

9. A container in accordance withclaim 8 bearing a half-tone printed image thereupon.

10. A container formed of a laminate comprising a tube of foamed polystyrene formed into a flattened sheet between about 5 and about 60 thousandths of an inch thick containing a multitude of closed cells and having an integral continuous skin, said sheet being bonded by an adhesive layer to a sheet of paper to form such laminate; said laminate having selected marginal surfaces thereof bonded adhesively to form such container; the polystyrene side of said laminate forming the interior surface of said container.

11. A container formed of seamed laminated sheet material consisting of a sheet of flexible foamed polystyrene secured by adhesive to a flexible sheet of paper; said laminated sheet material having overlapping marginal portions to form the seams of such container; said polystyrene sheet being several thousandths of an inch thick, having on each of opposite surfaces thereof a substantially integral continuous skin and containing throughout and between such skin surfaces a multitude of small closed cells; an adhesive layer between such overlapping marginal portions of such laminated sheet material, said foamed polystyrene having been removed from those of such marginal portions which are in engagement with the paper side of other marginal portions of said sheet material.

12. A novel seam construction joining two marginal portions of laminated sheet material, the latter material consisting of flexible foamed polystyrene sheet secured by adhesive to the inner face of flexible paper sheet, one such marginal portion consisting of the laminated sheet material having a layer of flexible foamed polystyrene adhered to a layer of flexible paper as aforementioned, and the other marginal portion thereof comprising the flexible paper sheet with said polystyrene sheet omitted therefrom and with its inner face overlapping and adhered to the outer face of the paper of said first-mentioned marginal portion, a layer of adhesive bonding said two paper layers, and the inner face of said last-mentioned flexible paper sheet adjacent said other marginal portion having the outer face of said polystyrene sheet secured thereto as aforementioned, said paper of said first-mentioned marginal portion terminating adjacent and without overlapping the outer face of said last-mentioned polystyrene sheet.

13. A novel seam construction joining portions of two thicknesses of laminated sheet material, one thickness of such seam construction consisting of flexible foamed polystyrene sheet having a multitude of closed air cells therein of predetermined air volume and secured by a layer of adhesive to flexible paper sheet, the other thickness of said seam construction comprising solid polystyrene flexible sheet having a substantially lower volume of air therein and thereby having a substantially higher density than said first-mentioned polystyrene sheet, said solid sheet having one face thereof secured by a layer of adhesive to flexible paper sheet, and having the other face thereof secured by a layer of adhesive to the paper sheet of said one thickness.

14. A flexible laminate consisting of a sheet of foamed polystyrene between about five and about sixty thousandths of an inch thick and containing a multitude of closed air cells, said sheet having a substantially continu ous integral skin showing a bright gloss on one surface thereof, and a flexible sheet of paper bonded only to the opposite surface thereof.

References fitted in the file of this patent UNITED STATES PATENTS 1,281,356 Harbeck Oct. 15, 1918 1,953,111 Home Apr. 3, 1934 1,983,875 Prindle Dec. 11, 1934 2,003,494 Reynolds June 4, 1935 2,370,419 Ray Feb. 27, 1945 2,434,106 Flood Jan. 6, 1948 2,537,644 Carr Ian. 9, 1951 2,555,380 Stuart et a1. June 5, 1951 2,590,221 Stevens Mar. 25, 1952 2,686,143 Fahrni Aug. 10, 1954 2,752,279 Alderfer June 26, 1956 2,766,920 Rawley Oct. 16, 1956 2,770,406 Lane Nov. 13, 1956 2,827,727 Lipsius Mar. 25, 1958 2,862,834 Hiler Dec. 2, 1958 OTHER REFERENCES Scientific American, September 1947, pages 119-121, article by Charles A. Breskin. 

11. A CONTAINER FORMED OF SEAMED LAMINATED SHEET MATERIAL CONSISTING OF A SHEET OF FLEXIBLE FOAMED POLYSTYRENE SECURED BY ADHESIVE TO A FLEXIBLE SHEET OF PAPER; SAID LAMINATED SHEET MATERIAL HAVING OVERLAPPING MARGINAL PORTIONS TO FORM THE SEAMS OF SUCH CONTAINER; SAID POLYSTYRENE SHEET BEING SEVERAL THOUSANDTHS OF AN INCH THICK, HAVING ON EACH OF OPPOSITE SURFACES THEREOF A SUBSTANTIALLY INTEGRAL CONTINUOUS SKIN AND CONTAINING THROUGHOUT AND BETWEEN SUCH SKIN SURFACES A MULTITUDE OF SMALL CLOSED CELLS; AN ADHESIVE LAYER BETWEEN SUCH OVERLAPPING MARGINAL PORTIONS OF SUCH LAMINATED SHEET MATERIAL, SAID FOAMED POLYSTYRENE HAVING BEEN REMOVED FROM THOSE OF SUCH MARGINAL PORTIONS WHICH ARE IN ENGAGEMENT WITH THE PAPER SIDE OF OTHER MARGINAL PORTIONS OF SAID SHEET MATERIAL. 